AutomationThe process or system which is control through

logic gates, relay logic, PLC’s, or computer.

AutomationThe process or system which is control through

logic gates, relay logic, PLC’s or computer

AutomationApplication

1. Quantity

2. Safety

3. Quality

4. Coast saving

Quantity1. Bottle filling industry use automation system to

increase their quantity. If human fill 1 bottle in 5 second.

1 minute: 1/5*60=12 bottles

1 Hour= 12*60=720 Bottles

2. While the machine fills 40-60 thousand in 1 hours

Safety1. For the filling of 40,000 bottles human strength

is required, so risk factor is involved for filling of bottles may be some of them will be damaged similarly for so many human safety is required.

2. While machine will automatically fill the bottles so less number of bottles will be damage.

Quality1. If human fills the bottles, some of them will be

fill more then the required level, some of them will be less than the required level.

2. While the machine fill the bottles exactly up to the required level. Machine scans the level and then pass it other wise it will be rejected and will be pull out from the system.

3. Similarly in production system machine will produce the same parts each time, however there will be error chances while process through human.

Coast saving1. In case of human how much quantity are filled,

so the net income will be according to the quantity.

2. While filling through machine, imagine how much quantity in increased, so it will increase the net income.

Disadvantages of Relay logics

1. Due to Huge size and complex circuits, for simple circuit a huge network of wires are connected .

2. Reprogramming. If someone wants to change the logic so he will reproduce the whole wiring system.

3. Troubleshooting is difficult, fault occurs often due to which machine down time is increases

4. It support only digital values i.e. high and low, it cannot support analogue values

Simatic1. In Siemens, PLC and automation are called simatic

2. Simatic are Siemens PLC and automation equipment.

3. Siemens produce siamtic in 1970

4. In first ranking ,33% Siemens PLC are used in the world

5. In second ranking,13% Allen Barley PLC are used in the world

Continued…1. China also produce Siemens PLC.

2. S7-200 CN, CN shows it is from china

3. Simatic controller is PLC

4. Simatic software is the software which is used for programming of PLC.

PLC Families1. Step 5 which is also called S-5, it is old PLC from

1970-1980. Its external case color is white and EPROM are orange color. It also have a cell cartridge.

2. Step 7 which is also called S-7

Advantaged of S5 over relay logic

1. It supports both analogue and digital values

2. High speed counting

Disadvantaged of S5

1. If battery is drained then reload PLC program from EPROM. It occurs mostly in S5

2. Low level language Program (Assembly Language is used for its programing)

3. Not fully online. PLC inputs and outputs can not monitored fully, some of them can be monitored.

Logo1. Siemens launch S7 family in 1990 which was

called logo, it was the first PLC of S7 family

2. Logo PLC have screen and keys (External case)

3. Software for logo programing is Logo Soft comfort

4. Its internal memory was 22kb only

5. Programming cable is Logo PC cable

Continued..1. 1-module have 8 digital inputs and 4 digital outputs

2. Logo support 8 Analogue inputs and 2 Analogue outputs

3. I/O s can be increased up to 100. logo supports maximum 100 inputs and outputs.

4. For stand alone system or independent system logo is the best solution.

5. Logo is cheaper price is only 12-15 thousand

6. Mostly sale out PLC of Siemens is logo.

Continued..1. Logo have its own HMI.

2. Disadvantage is only less number of inputs and output i.e. 100

Application1. Traffic signal, 90% in traffic signal logo is used

2. Mostly used in ATS, automatic transfer switch. It is used to transfer load from WAPDA to generator or vice versa.

3. Used in Textile industry

4. For stand alone system logo is the best solution

5. In new logo PLC Ethernet port is available

6. Logo can be interfaced or communicate with external Siemens HMI

S7-2001. Launched after Logo

2. Internal Memory 32Kb

3. Its memory can be extended with memory card

4. Supported Memory cards: 64kb, 128kb, 256kb

5. On board 14 Digital inputs and 10 digital outputs

6. 200 I/O’s are supported by expansion of module

Continued..1. Software for PLC Programming: Micro win

2. Communication cable: PPI cable (point to point interface) Apr. price: 20,000/

3. S7-200 can be interface with Siemens and non Siemens HMI.

4. S7-200 can not support SCADA (Supervisory control and data acquisition) system

Interfacing of Siemens PLC with Non Siemens Modules

1. To interface Siemens PLC with non Siemens Modules, GSD (general system description) file is required.

2. Every module have their own GSD file

3. It act like a translator, without installation of this file CPU will not recognize the module

S7-200Application

1. Every CNG station in Pakistan

2. Textile industry

3. Pharmaceuticals

4. Packaging

5. Mostly used in Pakistan, china equipment mostly have S7-200 PLC.

6. Basic Module start from Rs. 70,000/

S7-3001. S7-300 have separate CPU and Signal modules.

2. CPU do not have memory for data storing

3. PLC program is stored into external memory card

4. External Memory card: Mini card (supported up to 8MB)

5. Programing software: Simatic Manager

6. Programing cable: MPI (Multi point interface)

Continued

1. CPU Price: 3,50,000/ (Memory card and SM are not included)

2. S7-300 support Profi bus, fiber optic and ethernet.

3. Maximum number of input/output supported: 1024

4. S7-300 also support master-slave configuration

Continued…

1. Total 32 number of S7-300 can be supported in network.

2. This is called Dazy chain topology

3. When more then 31 slave is required then repeaters are required

4. Maximum Supported I/O’s in master-slave configuration: 17700

Continued…

1. Always program master CPU

2. In case of breakage in communication b/w master-slave or fault occurs in any network, whole system will be shutdown

3. S7-300 support SCADA (Supervisory control and data acquisition)

S7-300Application

1. Power Houses

2. Nuclear Power plant

3. Cement Industry

4. Food Industry

5. Fertilizer Industry

6. Oil & gas sector

S7-400

1. CPU price: 8 Lakh

2. Software: Simatic Manager

3. Support Profi bus communication

4. Support Master-slave configuration

5. Supported I/O’s: 2048

6. Support 31 slave network

7. Support DCS (Distributed control system)

Continued…

1. Siemens called DCS, PCS7 (Process control system-7).

2. S7-400 is redundant system

3. When one system fails, another system starts working

S7-1200

1. 2-3 years ago, Siemens launched, replacement of S7-200

2. All features are of S7-200

3. Software: TIA portal (Total Integrated Automation portal)

4. HMI can be designed in TIA portal

5. Support 250 I/O’s Expansion

Continued…

1. Internal memory: 256Kb

2. Memory extended by using Mini SD card up to 1MB

3. Programming cable: Ethernet

4. Module have 14 DI, 10 DO, 2 AI

5. Price is less than S7-200

6. Support Master-slave configuration through Ethernet cable

S7-300

1. Slot rule

Po

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Su

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ly

CPU IMIn

terf

ace

mo

du

le

4-11 (8 SM)Signal Module

Digital Input/outputAnalogue Input/output

FM

Fu

nct

ion

al M

od

ule

CP

Co

mm

un

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p

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sso

r

Continued…

1. PS, IM, FM and CP are optional

2. Functional module: when special function is required like encoder, closed loop control for positioning

3. Communication processor: when Ethernet supported drives are communicated with CPU, then Ethernet CP is used.

Rack configuration

1. Two types: Horizontal and vertical

2. In hot weather country horizontal configuration is used due to easy heat transfer

3. In cold weather country vertical configuration is used.

Digital Module address

DI

P0I0.0-I0.7

P1I1.0-I1.7

P2I2.0-I2.7

P3I3.0-I3.7

Digital Module address

DO

P4q4.0-I0.7

P5q5.0-q5.7

P6q6.0-q6.7

P7q7.0-q7.7

Digital Module address

P4 X

P5 X

P0 P2

P1 P3

P8 X

P9 X

P12 P14

P13 P15

Po

wer

Su

pp

ly

CPU IM-SSM

8*32=256

IM-RSM

8*32=256

IM-RSM

8*32=256

Continued…

1. IM used for communication with racks

2. S7-300 support 1024 I/O’s so IM-S and IM-R is used

Module

Model No.

Order number

Model No Order No

AI

DO

DO

DI

CPU

PS

SM331 A18*12BIT

SM322 DO16*RelAC120/230

SM322 DO16*RelAC120/230

SM321 DI32*DC24V

CPU315-2DP

PS307, 5A

6ES7 331-7KF02-0AB0

6ES7 322-1HH01-0AA0

6ES7 322-1HH01-0AA0

6ES7 321-1BL00-0AA0

6ES7 315-2AF02-0AB0

6ES7 307-1EA00-0AA0

Continued…

321- Digital input Module

322- Digital output Module

323- Digital input/output module

331- Analogue input module

332- Analogue output module

333- Analogue input/output module

Profibus1. Industrial communication protocol

2. Decentralized Peripheral (DP) mean profibus

3. 2 wire communication

4. Purple color

5. Profibus communicate through RS485, Shielded cable

6. Red-green wires

7. Red-A1, green-B1

8. Profibus can be used for interfacing PLC with NCU and HMI

Continued..1. Profibus connector have termination switch (ON

& OFF)

2. When the switch is ON, it means terminate the communication

3. Diagram for Master CPU interfacing with slave CPU

4. First and last PLC module switch should be ON, other will be OFF

Gates Basic1. AND Gate: Z=X*Y

2. OR Gate: Z=X+Y

3. NAND Gate: Z=X’+Y’

4. NOR Gate: Z=X’*Y’

5. XOR Gate: Z=X*Y’+X’*Y

6. XNOR Gate: Z=X*Y+X’*Y’

7. In English Language I: Input, Q: output

8. In German language E: Input, A: Output

9. Solve above Examples in Ladder

10. Next Presentation will be about Simatic Manager

Thank you